JP2024500325A - carbon dioxide capture - Google Patents

Abstract

The system for removing CO2 from a dilute gas mixture comprises: a frame comprising a plurality of structural members; and at least one packing section comprising one or more packing sheets; at least one fill area including a plurality of macrostructures and one or more fluids positioned at least partially below the at least one fill area and configured to retain a CO2 capture solution. a reservoir, at least one fan positioned to circulate the CO2-containing gas through the at least one fill area, and a liquid distribution system configured to flow the CO2 recovery solution to the at least one fill area. including.

Description

This disclosure describes systems, devices, and methods for capturing carbon dioxide.

Capturing carbon dioxide (CO ₂ ) from the atmosphere is one way to reduce greenhouse gas emissions and slow climate change. However, many technologies designed for _CO2 capture from point sources, such as flue gas from industrial facilities, are unable to capture CO2 from the atmosphere due to significantly lower _CO2 concentrations and the large volumes of air that need to be processed. Generally effective when capturing _CO2 . In recent years, progress has been made in discovering technologies that are better adapted to capturing _CO2 directly from the atmosphere. Some of these direct air capture (DAC) systems use solid adsorbents where the active agent is attached to a substrate. These DAC systems typically use a cyclic adsorption-desorption process in which a solid adsorbent is saturated with _CO2 and then releases the _CO2 using moisture or a thermal swing. and can be played. Although solid adsorbent DAC systems can have high cycle yields, large-scale deployment is difficult due to the maintenance requirements inherent in batch processing.

Other DAC systems use liquid adsorbents (sometimes referred to as solvents) to capture _CO2 from the atmosphere. An example of such a gas-liquid contact system is based on cooling tower design, where a fan is used to draw air across a large surface area packing wetted with a solution containing a liquid adsorbent. used. _CO2 in the air reacts with the liquid adsorbent. The thick solution is further processed downstream to regenerate the thin solution and release a stream of concentrated _CO2 . DAC systems designed based on cooling towers use existing supply networks and associated equipment, as well as some commercially available equipment, and are more efficient in certain environments than others. It is advantageous, in part, because it can be operated on. It is desirable that the DAC system be easily maintainable and operationally flexible.

In an exemplary implementation, a system for removing _CO2 from a dilute gas mixture comprises a frame comprising a plurality of structural members and at least one packing area comprising one or more packing sheets, the system comprising: a frame comprising a plurality of structural members; The one or more packing sheets are positioned at least partially below the at least one packing area and the at least one packing area and are configured to retain a CO ₂ capture solution. at least one fan positioned to circulate the CO ₂ -containing gas through the at least one packing section and supplying the CO ₂ recovery solution to the at least one packing section. a liquid distribution system configured to flow.

In aspects combinable with the exemplary implementation, the at least one packing section and the fan flow the _CO2- containing gas through the at least one packing section in a cross-flow configuration relative to the _CO2 recovery solution. configured.

In other embodiments that can be combined with any of the preceding embodiments, the at least one packing section and the fan direct the CO ₂ -containing gas in a countercurrent configuration relative to the CO ₂ recovery solution through the at least one packing section. Configured to flow through the area.

In other embodiments that can be combined with any of the preceding embodiments, the _CO2 recovery solution comprises KOH.

In other embodiments that can be combined with any of the preceding embodiments, the liquid distribution system includes one or more upper reservoirs positioned at or near the top of the frame; and one or more upper reservoirs. one or more redistribution systems positioned in the at least one fill area below the section and one or more lower sump sections positioned at or near the bottom of the frame.

In other embodiments that can be combined with any of the preceding embodiments, the one or more filler sheets have a first set of progressive passages at a first angle and a second set of progressive passages at a first angle greater than the first angle. and a second set of progressive passages at an angle.

In other embodiments that can be combined with any of the preceding embodiments, the first angle is 15 degrees and the second angle is 45 degrees or less.

In other embodiments that can be combined with any of the preceding embodiments, the flow of the CO ₂ recovery solution from at least one of the one or more reservoirs to the at least one packing section is in a membrane flow state. including.

In other embodiments that can be combined with any of the previous embodiments, the one or more filler sheets are provided with a hydrophilic surface coating.

In other embodiments that can be combined with any of the previous embodiments, the hydrophilic surface coating comprises a cellulose coating.

In other embodiments that can be combined with any of the previous embodiments, the cellulose coating comprises an ethylene vinyl acetate (EVA) layer and a cellulose layer.

In other embodiments that can be combined with any of the previous embodiments, the cellulose coating is applied to one or more layers of hydrophilic filler material with calendering.

In other embodiments that can be combined with any of the previous embodiments, a hydrophilic surface coating is applied to both sides of each of the one or more layers of hydrophilic filler material.

In other embodiments that can be combined with any of the previous embodiments, the hydrophilic surface coating comprises an acrylic coating.

In other embodiments that can be combined with any of the previous embodiments, the acrylic coating comprises at least one of a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion.

In other embodiments that can be combined with any of the previous embodiments, the acrylic coating comprises multiple acrylic layers.

In other embodiments that can be combined with any of the preceding embodiments, the plurality of acrylic layers comprises a first acrylic layer of a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion; a second acrylic layer of a urethane-acrylic hybrid copolymer mixed with a copolymer emulsion.

In other embodiments that can be combined with any of the previous embodiments, the hydrophilic surface coating comprises a fouling layer.

In other embodiments that can be combined with any of the previous embodiments, one or more filler sheets include a hydrophilic surface treatment.

In other embodiments that can be combined with any of the previous embodiments, the hydrophilic surface treatment comprises at least one of plasma treatment, flame treatment, corona treatment, or chemical treatment.

In other embodiments that can be combined with any of the previous embodiments, the plurality of macrostructures comprises at least one of corrugations, grooves, herringbones, or channels.

In other embodiments that can be combined with any of the previous embodiments, the one or more filler sheets further comprise a plurality of microstructures.

In other embodiments that can be combined with any of the previous embodiments, the plurality of microstructures comprises a plurality of ridges that are non-parallel to the corrugations.

In other embodiments that can be combined with any of the previous embodiments, the corrugations are aligned with the direction of flow of the _CO2 recovery solution from the one or more reservoirs to the at least one packing section.

In other embodiments that can be combined with any of the preceding embodiments, the plurality of microstructures comprises at least one of ridges, depressions, pores, etchings, granules, fibers, perforations, or combinations thereof. .

In other embodiments that can be combined with any of the previous embodiments, the ridge comprises a plurality of intersecting flow ridges.

In other embodiments that can be combined with any of the preceding embodiments, the one or more filler sheets include at least one hydrophilic coating covering at least a portion of the one or more filler sheets.

In other embodiments that can be combined with any of the previous embodiments, the at least one hydrophilic coating comprises a cellulose layer and at least one of an EVA layer or a PVC adhesive layer.

In other embodiments that can be combined with any of the previous embodiments, the at least one hydrophilic coating comprises at least one acrylic coating.

In other embodiments that can be combined with any of the previous embodiments, the at least one acrylic coating comprises at least one of a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion.

In other embodiments that can be combined with any of the preceding embodiments, the at least one acrylic coating comprises a first acrylic layer comprising a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion; a second acrylic layer comprising a urethane-acrylic hybrid copolymer mixed with an acrylic copolymer emulsion.

In other embodiments that can be combined with any of the preceding embodiments, the urethane-acrylic hybrid copolymer is combined with a self-crosslinking acrylic copolymer emulsion of 20/80, 80/20, or 50/50. Mix in one proportion.

In other embodiments that can be combined with any of the previous embodiments, the at least one hydrophilic coating comprises a fouling layer.

In other embodiments that can be combined with any of the previous embodiments, one or more filler sheets include a hydrophilic material composition.

In other embodiments that can be combined with any of the previous embodiments, the hydrophilic material composition comprises a PVC resin or a vinyl compound.

In other embodiments that can be combined with any of the previous embodiments, the hydrophilic material composition is formed into one or more layers of hydrophilic filler material by a mold and vacuum forming process.

In other embodiments that can be combined with any of the preceding embodiments, the CO ₂ capture solution comprises a low surface tension CO ₂ capture solution.

In other embodiments that can be combined with any of the previous embodiments, the low surface tension CO ₂ capture solution comprises an atomized CO ₂ capture solution that is sprayed onto at least one packing area.

In other embodiments that can be combined with any of the preceding embodiments, the low surface tension CO ₂ capture solution includes a rate-enhancing additive.

In other embodiments that can be combined with any of the preceding embodiments, the speed-enhancing additive is carbonic anhydrase, piperazine, MEA, DEA, zinc triazacycyl, zinc tetraazacycyl, copper glycinate, cobalt hydroxopentamine. at least of perchlorate, formaldehyde hydrate, sucrose, fructose, glucose, phenol, phenolate, glycerin, arsenite, hypochlorite, hypobromite, or other oxyanionic species Including one.

In other embodiments that can be combined with any of the previous embodiments, the rate-enhancing additive is immobilized in one or more capsules within the CO2 recovery solution.

In other embodiments that can be combined with any of the previous embodiments, one or more filler sheets include a speed-enhancing additive.

In other embodiments that can be combined with any of the preceding embodiments, the speed-enhancing additive is carbonic anhydrase, piperazine, MEA, DEA, zinc triazacycyl, zinc tetraazacycyl, copper glycinate, cobalt hydroxopentamine. at least of perchlorate, formaldehyde hydrate, sucrose, fructose, glucose, phenol, phenolate, glycerin, arsenite, hypochlorite, hypobromite, or other oxyanionic species Including one.

In other embodiments that can be combined with any of the previous embodiments, the one or more filler sheets are provided with a speed-enhancing coating that includes a speed-enhancing additive.

In other embodiments that can be combined with any of the previous embodiments, the one or more filler sheets include a plurality of dissolvable solids.

In other embodiments that can be combined with any of the previous embodiments, the plurality of soluble solids comprises at least one of calcium carbonate (CaCO ₃ ) or potassium carbonate (K ₂ CO ₃ ).

In other embodiments that can be combined with any of the preceding embodiments, the _CO2 recovery solution comprises a caustic recovery solution.

In another exemplary implementation, a method of operating a system for capturing carbon dioxide (CO ₂ ) includes directing a dilute gas mixture containing CO ₂ to one or more fill areas of a gas-liquid contactor. flowing the recovered solution over one or more packing sections of the gas-liquid contactor, the one or more packing sections including at least one packing sheet and at least one packing section; The packing sheet comprises a plurality of macrostructures, including the steps of: reacting the diluted gas mixture with a recovery solution to produce _CO2 diluted gas; and releasing the _CO2 diluted gas from the gas-liquid contactor. including the step of operating the fan.

In embodiments combinable with exemplary implementations, at least one filler sheet comprises a hydrophilic coating covering at least a portion of the at least one filler sheet.

In other embodiments that can be combined with any of the previous embodiments, the hydrophilic coating comprises at least one acrylic coating.

In other embodiments that can be combined with any of the previous embodiments, the at least one acrylic coating comprises at least one of a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion.

In other embodiments that can be combined with any of the preceding embodiments, the at least one acrylic coating comprises a first acrylic layer comprising a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion; a second acrylic layer comprising a urethane-acrylic hybrid copolymer mixed with an acrylic copolymer emulsion.

In other embodiments that can be combined with any of the preceding embodiments, the urethane-acrylic hybrid copolymer is combined with a self-crosslinking acrylic copolymer emulsion of 20/80, 80/20, or 50/50. Mix in one proportion.

In other embodiments that can be combined with any of the previous embodiments, the hydrophilic coating comprises a cellulosic layer and an adhesive layer comprising at least one of an EVA or PVC adhesive.

In other embodiments that can be combined with any of the previous embodiments, the hydrophilic coating comprises a fouling layer.

In other embodiments that can be combined with any of the previous embodiments, the plurality of macrostructures comprises at least one of corrugations, grooves, herringbones, or channels.

In other embodiments that can be combined with any of the previous embodiments, at least one filler sheet comprises a plurality of microstructures.

In other embodiments that can be combined with any of the previous embodiments, the plurality of microstructures comprises at least one of perforations, ridges, depressions, pores, etchings, granules, or fibers.

In other embodiments that can be combined with any of the previous embodiments, the ridge comprises a plurality of intersecting flowing ridges.

In other embodiments that can be combined with any of the preceding embodiments, flowing the dilute gas mixture comprising _CO2 into the one or more packing sections of the gas-liquid contactor comprises and drawing the diluted gas mixture into an intake plenum positioned below the storage area.

In other embodiments that can be combined with any of the preceding embodiments, flowing the dilute gas mixture comprising _CO2 into the one or more packing sections of the gas-liquid contactor comprises directing the dilute gas mixture to 1 circulating through one or more packing sections in an average gas flow direction that is parallel to an average liquid flow direction of the collected solution.

In other embodiments that can be combined with any of the preceding embodiments, flowing the recovery solution over one or more packing sections of the gas-liquid contactor comprises flowing the recovery solution from 0 L/m ² s to 10 L/m 2 s. Including flowing at liquid filling velocities ranging up to m ² s.

In other embodiments that can be combined with any of the previous embodiments, at least one filler sheet comprises a plurality of dissolvable solids.

In other embodiments that can be combined with any of the previous embodiments, the plurality of soluble solids comprises at least one of calcium carbonate (CaCO ₃ ) or potassium carbonate (K ₂ CO ₃ ).

In other embodiments that can be combined with any of the preceding embodiments, the recovery solution comprises a caustic solution.

In another exemplary implementation, an apparatus for dispensing a CO ₂ capture solution comprises a packing area comprising a plurality of packing sheets positioned to contact the CO ₂ capture solution and the CO ₂ -containing gas. , the distance from the first end of the filling area to the second end of the filling area is between 2 meters and 10 meters.

In embodiments combinable with exemplary implementations, the liquid filling rate ranges from 0 L/m ² s to 10 L/m ² s.

In other embodiments that can be combined with any of the preceding embodiments, the _CO2 recovery solution comprises a caustic recovery solution.

In other embodiments that can be combined with any of the preceding embodiments, at least one filler sheet of the plurality of filler sheets comprises a plurality of macrostructures.

In other embodiments that can be combined with any of the previous embodiments, the plurality of macrostructures comprises at least one of corrugations, grooves, herringbones, or channels.

In other embodiments that can be combined with any of the previous embodiments, at least one of the corrugations has a width of 0.5 inches to 4 inches.

In other embodiments that can be combined with any of the preceding embodiments, each filler sheet of the plurality of filler sheets is positioned at least 0.2 inches apart from other filler sheets of the plurality of filler sheets. be done.

In other embodiments that can be combined with any of the previous embodiments, at least one filler sheet of the plurality of filler sheets comprises a plurality of microstructures.

In other embodiments that can be combined with any of the previous embodiments, each microstructure of the plurality of microstructures is less than 10 mm wide.

In other embodiments that can be combined with any of the preceding embodiments, the microstructures of each of the plurality of microstructures are at least one of ridges, depressions, pores, etchings, granules, fibers, or perforations. molded.

In other embodiments that can be combined with any of the previous embodiments, each of the ridges has a length that is oriented at an angle non-parallel to the flow direction of the CO ₂ capture solution.

In other embodiments that can be combined with any of the preceding embodiments, the non-parallel angles include perpendicular angles.

In other embodiments that can be combined with any of the preceding embodiments, at least one filler sheet of the plurality of filler sheets has at least one hydrophilic coating covering at least a portion of the at least one filler sheet. include.

In other embodiments that can be combined with any of the preceding embodiments, the at least one hydrophilic coating comprises a first hydrophilic coating comprising a cellulose layer and at least one of an EVA layer or a PVC adhesive layer. .

In other embodiments that can be combined with any of the previous embodiments, the cellulose layer comprises a cellulose layer thickness between 50 μm and 100 μm.

In other embodiments that can be combined with any of the previous embodiments, the EVA layer comprises an EVA layer thickness of at least 30 μm.

In other embodiments that can be combined with any of the previous embodiments, the at least one hydrophilic coating comprises at least one acrylic coating.

In other embodiments that can be combined with any of the previous embodiments, the at least one acrylic coating comprises at least one of a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion.

In other embodiments that can be combined with any of the preceding embodiments, the at least one acrylic coating comprises a first acrylic layer comprising a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion; a second acrylic layer comprising a urethane-acrylic hybrid copolymer mixed with an acrylic copolymer emulsion.

In other embodiments that can be combined with any of the preceding embodiments, a urethane-acrylic hybrid copolymer coats a self-crosslinking acrylic copolymer emulsion.

In other embodiments that can be combined with any of the preceding embodiments, the urethane-acrylic hybrid copolymer is combined with a self-crosslinking acrylic copolymer emulsion of 20/80, 80/20, or 50/50. Mix in one proportion.

In other embodiments that can be combined with any of the previous embodiments, the at least one hydrophilic coating comprises a fouling layer.

In other embodiments that can be combined with any of the previous embodiments, the plurality of filler sheets comprises a plurality of dissolvable solids.

In other embodiments that can be combined with any of the previous embodiments, the plurality of soluble solids comprises at least one of calcium carbonate (CaCO ₃ ) or potassium carbonate (K ₂ CO ₃ ).

In another example implementation, a method of manufacturing a filler region includes providing a filler material feedstock that includes a filler material and shaping the filler material to form a plurality of macrostructures. include.

A combinable aspect of the exemplary implementation further includes applying a hydrophilic coating to the filler material.

In other embodiments that can be combined with any of the previous embodiments, applying the hydrophilic coating includes applying at least one acrylic coating.

In other embodiments that can be combined with any of the previous embodiments, the at least one acrylic coating comprises at least one of a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion.

In other embodiments that can be combined with any of the preceding embodiments, applying the at least one acrylic coating coats the first acrylic layer of the urethane-acrylic hybrid copolymer or self-crosslinking acrylic copolymer emulsion. and applying a second acrylic layer of a urethane-acrylic hybrid copolymer mixed with a self-crosslinking acrylic copolymer emulsion.

In other embodiments that can be combined with any of the preceding embodiments, applying the hydrophilic coating comprises heating the adhesive layer to a bonding temperature, applying the adhesive layer to the filler material, and applying the hydrophilic coating to the filler material. It involves placing a layer over the adhesive layer and filler material and pressing the cellulose layer onto the adhesive layer using a heated roller.

In other embodiments that can be combined with any of the previous embodiments, the adhesive layer comprises ethylene vinyl acetate (EVA) and an adhesive layer thickness of at least 30 μm.

In other embodiments that can be combined with any of the previous embodiments, the adhesive layer comprises a PVC adhesive.

In other embodiments that can be combined with any of the previous embodiments, the cellulose layer comprises a cellulose layer thickness of 50 μm to 100 μm.

In other embodiments that can be combined with any of the previous embodiments, the filler material comprises a plastic substrate.

In other embodiments that can be combined with any of the preceding embodiments, the plastic substrate comprises PVC.

In other embodiments that can be combined with any of the previous embodiments, shaping the filler material includes shaping the plastic substrate using a set of calender rollers.

Other aspects that can be combined with any of the previous aspects include forming a plurality of microstructures in the filler material.

In other embodiments that can be combined with any of the preceding embodiments, forming a plurality of microstructures in the filler material comprises at least one of ridges, depressions, pores, etchings, granules, fibers, or perforations. Including forming one.

In other embodiments that can be combined with any of the previous embodiments, each microstructure of the plurality of microstructures is less than 10 mm wide.

In other embodiments that can be combined with any of the preceding embodiments, forming a plurality of microstructures in the filler material comprises introducing a plurality of dissolvable solids into the filler material and a plurality of dissolvable solids. and removing at least a portion of the solid with a dissolution fluid.

In other embodiments that can be combined with any of the previous embodiments, the plurality of soluble solids comprises at least one of calcium carbonate (CaCO ₃ ) or potassium carbonate (K ₂ CO ₃ ).

In other embodiments that can be combined with any of the previous embodiments, forming the plurality of microstructures in the filler material includes mechanically etching the filler material.

In other embodiments that can be combined with any of the preceding embodiments, forming a plurality of microstructures in the filler material includes introducing a plurality of surface particles into the filler material, the surface particles comprising: Contains at least one of fibers or granules.

Other embodiments that can be combined with any of the previous embodiments further include applying a surface treatment to the filler material, the surface treatment comprising at least one of plasma treatment, flame treatment, or corona treatment.

Other embodiments that can be combined with any of the previous embodiments further include applying speed-enhancing additives to the filler material.

In other embodiments that can be combined with any of the preceding embodiments, shaping the filler material to form the plurality of macrostructures includes vacuum forming and thermoforming the filler material.

In other aspects that can be combined with any of the previous aspects, shaping the filler material to form the plurality of macrostructures includes forming at least one of corrugations or channels.

Implementations of systems and methods for carbon dioxide capture according to the present disclosure may include one, some, or all of the following features. For example, a packing with the features described in the present invention is specifically designed for commercial DAC applications, and thus reduces air volume, packing depth, etc. without appreciably sacrificing _CO2 uptake capacity. , liquid flow, and air contactor footprint. DAC packing design criteria that reflect good performance include low static pressure design, ability to distribute liquid evenly through the packing height, low fouling capability, increased air contact efficiency, and less material requirements. There are efficiency effects of larger fill sizes, and manufacturability. Through the use of the features described in this invention, reducing the amount of filler volume required reduces the size and size of commercial air contactors required for a given plant recovery rate. If/or the number is reduced, improving the reliability of the filler material under DAC operating conditions such as those mentioned herein will provide a longer service life and a reduction in the cost of maintenance. It should be.

The details of one or more implementations of the subject matter described in this disclosure are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will be apparent from the specification, drawings, and claims.

FIG. 3 shows an illustrative example of an interface between a packing and other elements of a gas-liquid contactor. FIG. 3 shows an illustrative example of an interface between a packing and other elements of a gas-liquid contactor. 1 illustrates an example gas-liquid contactor according to the present disclosure. FIG. FIG. 3 depicts an exemplary effect of contact angle on the flow conditions of the collected solution at the packing surface. FIG. 3 shows examples of contact angles of coating and recovery solutions on uncoated surfaces, on surfaces coated with one or more acrylic layers, and on surfaces with fouling layers. FIG. 2 illustrates an exemplary cellulose-coated filling. FIG. 3 is a diagram illustrating an exemplary calendering process. FIG. 3 illustrates an exemplary corrugated filler sheet with corrugated edges and smooth edges. FIG. 3 illustrates an exemplary packing area with packing sheets forming progressive passageways. It is a figure which shows the example of the microstructure in a filler sheet. Exemplary packing sheets with cross-flow ridges, exemplary packing sheets with flow direction ridges, and exemplary packing without ridges (flat) at high and low flow rates of collection solution. It is a figure which compares the contact area of a sheet|seat. FIG. 2 illustrates an exemplary approach for forming microstructures in a filler sheet using soluble solids. FIG. 3 illustrates the interaction of a sprayed solution with a liquid interface. 1 is a schematic diagram of an example control system for a gas-liquid contactor system. FIG.

The present disclosure describes systems and methods for recovering _{CO 2 from} the atmosphere or other fluid source (such as air) containing CO ₂ with a gas-liquid contactor. In some embodiments, the gas _- liquid contactor includes a packing ₍ herein referred to as " (also referred to as "fillers"). The packing can include a plurality of packing sections, and each packing section can include one or more packing sheets. The filler sheets can be arranged to form filler areas that can be three-dimensional structures of filler (eg, blocks, columns, cubes, etc.). In some embodiments, the packing is hydrophilic rather than hydrophobic to maximize contact between the liquid CO ₂ sorbent and the CO ₂ -containing air stream flow over at least a portion of the packing. (i.e., as a hydrophilic filler).

The exemplary implementations of packing in this disclosure, in preferred implementations, are designed for DAC applications, such as traditional cooling tower applications or packed column applications. There are many such design considerations. For example, the packings produced for packed columns or "packed towers", also known as "scrubbers" or "gas scrubbers" in chemical processing plants, are used for _CO2 concentrations of approximately 5-15% v/v. Designed. Therefore, a significantly smaller volume of gas is required for processing in a chemical process packed column to recover an equivalent amount of _CO2 from air using a DAC. As such, recovery kinetics in chemical processing facilities are generally more favorable compared to absorbing dilute _CO2 concentrations as in DAC systems.

Chemical process countercurrent packed columns face certain problems, such as flooding. Flooding is a phenomenon in which gas moving in one direction in a packed column entrains liquid moving in the opposite direction in the packed column. Flooding is undesirable because, in addition to large pressure drops across the packed column, it can cause other effects that are detrimental to the performance and stability of the absorption process. The ratio of diameter to L/G velocity in a counterflow absorber column in a chemical process is not the same as in a counterflow air contactor, so the counterflow configuration in an air contactor presents the same problems as in a chemical scrub column. I don't come across it. Therefore, while both CCS and DAC technologies capture _CO2 from gaseous streams, the process designs for both technologies are different due to their different feedstock and process conditions.

There are also many design considerations compared to traditional cooling towers. For example, commercially available packings from the cooling tower industry are available for use with water and to maximize heat transfer without much consideration for mass transfer, which is important for DAC systems. It is designed to. In cooling towers, a structural framework supports the packing that is stacked or suspended within the packing spaces of the cooling tower cells. Commercially available fillers can be formed from metal sheets (eg, steel) or plastics such as PVC. Although some structured fillers formed from metals have excellent wetting properties, metal fillers are expensive and heavy. PVC is commonly used in cooling towers because it is lightweight, moldable, affordable, and resistant to most chemicals.

Two types of structured packing are traditionally used in cooling towers: splash packing and film packing. Splash fillers typically consist of evenly spaced, horizontally positioned splash bars. The splash bars break the liquid flow and cause a cascading flow of liquid through the spaces between the splash bars and to other splash bars, creating droplets and wet surfaces that react with the gas. The main problem with using splash fillers is that the splash bar is prone to sag that can impede gas flow, leading to liquid channels and reducing performance. The splash bar system also has a very small specific surface area. Splash-loading materials used on their own for DAC applications require significantly higher volumes of recovery solution to allow for equivalent mass transfer constraints and reaction kinetics.

Membrane fillers are designed to promote the spreading of liquid into a thin film at the surface of the filler. This allows maximum exposure of liquid to gas. Comparing droplet-based fillers to membrane-based fillers, membrane-based fillers are generally more compatible with DAC because they have the ability for more efficient mass transfer in filler space per unit volume. Membrane fillers offer a much higher specific surface area to volume ratio (“specific surface area” in m ² /m ³ ) than droplet fillers. High specific surface area is not only important for the exposure of _CO2 to the surface of the collection solution, but also has cost and construction implications. The smaller the specific surface area, the more packing is required to absorb a large proportion of _CO2 from the air. More filling results in an increase in the complexity and size of the structural skeleton required to hold the filling.

The characteristics that may be utilized to change the surface roughness of the DAC packing may be different from the characteristics of the cooling tower packing. Commercially available cooling tower packings with surface roughness often result in biological fouling problems in the cooling tower. Biological fouling occurs because open system conditions with water can create a favorable environment for microbial growth. In contrast, DAC systems implementing recovery solutions that have, for example, a high pH or contain caustic or carbonate solutions do not share this concern and are therefore more A wide range of features can be used.

Generally, commercially available cooling towers have a primary purpose of heat transfer and must efficiently move large volumes of air to remove process heat from the cooling water. However, given that the goal of the DAC is CO ₂ mass transfer rather than heat transfer, in combination with dilute CO ₂ concentrations (less than 1v/v%) in the air that must be treated with the DAC, significant amounts of In order to recover CO ₂ , a large volume of air must be processed by the air contactor of the DAC system. Because the purpose of DAC is the mass transfer of dilute amounts of CO ₂ from a volume of air rather than heat transfer, more packing is required for DAC applications than in cooling towers for a given density of packing. required for. The depth to which air travels through the packing in a gas-liquid contactor (e.g. packing depth) can range from 2 to 10 meters for direct air recovery, which is typically used in cooling towers. The fill depth is greater than just a few feet.

The gas-liquid contactors (such as air contactors) of the DAC system become intermittently wet due to the use of a liquid flow that is substantially less than that of the cooling tower. Some advantages of lower liquid flow are reduced pumping equipment, equipment, as well as pump and fan power requirements. Packings coming from the cooling tower industry are designed for substantially higher liquid filling rates than those used in DACs. For example, a cooling tower packing may be designed for a liquid filling rate of approximately 4.1 L/m ² s. Because cooling towers are usually coupled to a process, they typically operate with sufficient continuous flow for maximum heat transfer, and process efficiency increases as the cooling water supply temperature decreases. As a result, cooling towers have no incentive to operate with small liquid flows where there is a risk of reduction in heat transfer through non-uniform wetting of the packing. The liquid to gas ratio for DAC applications is about 10 times lower than for cooling tower applications. For example, the liquid to gas ratio for DAC applications can range from 0.6 to 0.8 based on mass flow.

The packing is the core component of the air contactor in the DAC system. Currently available commercial cooling tower packings are suboptimal for DAC applications, and their use is limited by larger air volumes, packing depths, and air contactor footprints (e.g., required packing Other aspects of the DAC system need to be modified, such as the material spacing and structural framework). There are at least two areas in which standard commercially available cooling tower packing elements are less effective for DAC: specific surface area and liquid hold-up efficiency.

For the mass transfer of CO ₂ from gas to liquid, often measured in DAC applications by CO ₂ capture flux, the key properties that factor into the flux equation are the specific surface area of the packing material and the liquid hold-up efficiency. It is the directly associated liquid-gas interface surface area.

The liquid hold-up efficiency of a filler is determined by the physical wettability, which is directly related to the surface energy, and the range over which liquid travels from the top to the bottom of the filler, determined by the shape and surface structure of the filler. determined in part by the completeness of Compared to metallic materials, PVC has lower surface energy resulting in larger contact angles and reduced wetting. Because DAC uses low liquid flow rates, surface wettability can be much more critical to performance than in cooling tower applications.

Commercially available cooling tower packings are specifically designed to achieve sufficient wetting under large liquid loads to meet heat transfer purposes. Thereby, the cooling tower packing showed insufficient wetting for small liquid filling rates of interest for DAC applications. At low liquid filling rates, the recovered solution tends to trickle and can form trails as it travels down the cooling tower packing. Insufficient wetting caused by the trickle of collection solution can result in unnecessarily low mass transfer, higher pump flow rates to increase liquid flow, and larger air contactor footprint. More importantly, insufficient wetting by the recovery solution may result in low _CO2 uptake.

The properties of the CO ₂ capture solution are also important considerations when designing packing for DAC systems. CO ₂ capture solutions are more viscous and denser than water (or treated water) and the like traditionally used in cooling tower applications. In fact, for the packing designed for DAC, the low concentration of CO ₂ in the ambient air requires a large air flow rate and a small pressure drop in the packing (compared to a conventional cooling tower). ) provides a large gas-liquid interface area at low solution flow rates. This reduction in solution flow rate can change the overall flow pattern from membrane flow to trickle flow, which reduces the amount of gas-liquid available for mass exchange from _{CO2 -} containing air to CO2 capture solution. There is a possibility of reducing the interface area. The flow rate at which this transition occurs depends on many factors, including the free energy of the solid surface of the packing and the density, viscosity, and surface tension of the CO ₂ capture solution. These properties in CO ₂ capture solutions are due in part to the high concentration of dissolved adsorbents such as caustic adsorbents (e.g., KOH or NaOH), which reduce the amount of water that is typically liquid in cooling tower applications. Different from characteristics.

For example, the density and viscosity of CO ₂ capture solutions can vary depending on the composition and temperature of such solutions. For example, at temperatures from 20 °C to 0 °C, a recovery solution containing 1 M KOH and 0.5 M K ₂ CO ₃ has a density in the range of 1115-1119 kg/m ³ and a range of 1.3-2.3 mPa-s. viscosity. In another example, a recovery solution containing 2M KOH and 1M K ₂ CO ₃ has a density ranging from 1260 to 1266 kg/m ³ and from 1.8 to 3.1 mPa-s at temperatures from 20 °C to 0 °C. and a range of viscosities. In comparison, at temperatures from 20°C to 0°C, water has a density of 998-1000 kg/m ³ and a viscosity of 1.0-1.8 mPa-s.

These features maximize the area of the gas-liquid interface at liquid filling rates from 0 L/m ² s to 10 L/m ² s, which can be effective for CO ₂ capture, while reducing large air This poses an opportunity to exploit the physical differences between these solutions to develop DAC-specific packing materials (i.e., packings) that exhibit small pressure drop due to throughput. For example, a DAC-specific fill may be operable for low liquid fill rates that may range from 0.5 L/m ² s to 2.5 L/m ² s. Such a filler provides better utilization of the filler surface area (reducing overall material costs) and reduces solution pump and fan power requirements. Such packing material depends on the number of gas-liquid contactor systems required for a given plant capacity, the amount of packing material required per air contactor, and sufficient _CO2 uptake. The required depth of air travel can be reduced.

Therefore, it is desirable to design and manufacture completely and uniformly wetted packings given the characteristic process conditions of DAC, including low liquid filling rates and diluent gas concentrations. Packings designed for DAC applications reduce at least one of the following: air volume, packing depth, liquid flow, and air contactor footprint without appreciably sacrificing _CO2 uptake capacity. The ability to reduce

1A and 1B illustrate illustrative examples of interfaces between packing 106 and other elements of gas-liquid contactors 100a, 100b (collectively and individually designated 100) according to the present disclosure. Gas-liquid contactor 100 includes a liquid distribution system 104, a fan 112 and its associated motor, a gas inlet 118, a CO ₂ recovery solution 114, a fill 106, and a lower sump 110. obtain. In some implementations (not shown), the gas-liquid contactor 100 includes a housing that partially encloses other elements of the gas-liquid contactor 100 and provides structural stability to the gas-liquid contactor 100. A frame with structural members provided therein. The liquid distribution system 104 may include a set of nozzles, an upper liquid reservoir 105, a pressurized header, or a combination thereof configured to distribute the CO ₂ capture solution 114 to the packing 106. For example, the top reservoir 105 can hold a CO ₂ recovery solution 114 and a nozzle positioned in the floor of the top reservoir 105 can flow the CO ₂ capture solution 114 into the packing 106 . The CO ₂ recovery solution 114 can flow through the packing material through gravity and can be collected at the bottom sump 110 .

The gas-liquid contactor 100a of FIG. 1A includes a packing section 106 and a fan 112 configured to flow a CO ₂ recovery solution 114 in a countercurrent configuration (also known as countercurrent) to the CO ₂ -containing air. Equipped with. In a countercurrent configuration, the CO ₂ capture solution 114 can flow through the packing 106 in a direction that is substantially parallel to and opposite to _{the CO 2 -containing} air. The gas-liquid contactor 100b of FIG. 1B includes a packing section 106 and a fan 112 configured to flow the CO ₂ recovery solution 114 in a cross-flow configuration with the CO ₂ -containing air. In a cross-flow configuration, the CO ₂ capture solution 114 can flow through the packing 106 in a direction that is substantially non-parallel (eg, perpendicular) to the CO ₂ -containing air.

The CO2 recovery solution 114 can be transferred from the bottom sump 110 for recirculation, for downstream processing (e.g., for regeneration), or for a combination thereof (e.g., liquid (can be pumped to distribution system 104). A gaseous stream (e.g., CO2-laden air) flows into the gas intake 118, through the fill 106, and out of the outlet of the gas-liquid contactor 100 by operating the fan 112 and its associated motor. be able to. In some cases (not shown), at least a portion of the outlet of the gas-liquid contactor 100 is configured to prevent the CO ₂ recovery solution 114 from exiting the gas-liquid contactor 100 with the gas flow. , covered by a drift eliminator material positioned between the filler 106 and the outlet. In some cases, gas inlet 118 may include an inlet louver, a protective screen, or a combination thereof.

Gas-liquid contactor configurations using packing as described in this disclosure can be used in one or more commercial applications, including, but not limited to, chemical scrubbers, HVAC systems, and cooling towers. Can include available gas-liquid contacting equipment. The packing can be designed and positioned within the gas-liquid contactor to allow liquid distribution and gas flow in one or more of a cross-flow configuration or a counter-flow configuration. In some implementations, the gas-liquid contactor may include a blower instead of or in addition to a fan to draw in the CO2 _- containing air.

FIG. 2 shows a schematic diagram of an exemplary gas-liquid contactor 200 according to the present disclosure. As shown in this schematic diagram, the gas-liquid contactor 200 includes a frame 202 (e.g., a combination of interconnected structural members 201) that provides structural support and stability to the gas-liquid contactor 200. ) and a housing 216 at least partially open to the atmosphere, for example for support of the illustrated components.

One or more upper reservoirs 204 are formed in or positioned within the frame 202 at or near the top of the frame 202. Each upper liquid reservoir 204 can at least partially enclose or store a CO ₂ capture solution 214 (eg, a CO ₂ adsorbent) therein. When stored (at least temporarily) in the upper liquid reservoir 204, the CO ₂ capture solution 214 flows downward (e.g., through pump flow, gravity flow, or both) into the fill 206 (plenum). separated by 208) and ultimately positioned to be circulated to one or more lower sump 210. Lower reservoir 210 may be positioned adjacent or proximate to the lower portion of frame 202. Filler 206 may include one or more filler areas that include a set of filler sheets. The set of filler sheets can form a filler area that is a three-dimensional structure of filler (eg, block, column, cube, etc.).

As the CO ₂ recovery solution 214 is circulated through the packing 206, the CO ₂ -laden air is passed through the packing 206 to contact the CO ₂ recovery solution 214, through the plenum 208, and into the surrounding environment _. It is circulated as air (eg, by fan 212). By contacting these two liquids (eg, in a cross-flow configuration as shown), the CO ₂ in the CO ₂ -containing air is transferred to the CO ₂ capture solution 214 . In some implementations (not shown), one or more redistribution systems are provided below one or more upper reservoirs, between one or more packing areas, or between packing sheets. It can be positioned between. The redistribution system may include alternative fills, trickle fills, splash fills, spray nozzles and piping, liquid reservoirs and nozzles, or combinations thereof.

In some embodiments, the CO ₂ capture solution 214 and the CO ₂ -containing air may be contacted in a countercurrent configuration (not shown). In implementations that include a countercurrent configuration, _CO2- containing air enters the fill 206 at or near the lower sump 210. The CO ₂ -containing air is circulated through the packing 206 in a mean flow direction that is parallel and countercurrent to the mean flow direction of the CO ₂ recovery solution 214 . For example, the CO ₂ -containing air can have an average flow direction that is vertically upward through the packing 206 as opposed to the CO ₂ capture solution 214 that has an average flow direction that is vertically downward. In some counterflow configurations, an intake plenum may be positioned below the fill 206 and adjacent to where the CO2 _- containing air enters. In some cases, a discharge plenum may be positioned above the packing 206.

A gas-liquid contactor in a counter-current configuration may include a recovered solution distribution system positioned at least partially below a fan that draws _CO2- containing air into an intake plenum. The recovered solution distribution system may include distribution piping that feeds the recovered solution into a set of nozzles or spargers that distribute it across the packing 206. In some cases, the collected solution distribution system in a countercurrent configuration can gravity feed the collected solution into the packing 206.

A lower sump 210 at the bottom of the gas-liquid contactor 200 acts as a collection tank for the CO ₂ recovery solution 214 where the solution is collected and then transferred to the contactor to recover more CO ₂ It may be pumped back for distribution across the charge, pumped to a downstream process for further processing, or a combination thereof.

In some cases, lowering the surface tension of the CO ₂ capture solution 214 to approach that of water will improve the solution's ability to wet the fill material. In some cases, lowering the surface tension of the CO ₂ capture solution 214 to approach that of water may be accomplished by diluting the concentration or adding surfactants.

In addition to process flow in the gas-liquid contactor system, process flow in any downstream process to which the gas-liquid contactor system is fluidly coupled is controlled by one or more flow control systems ( For example, the control system 999) can be used to flow. A flow control system includes one or more flow pumps, fans, blowers, or solids conveyors for moving the process fluid, one or more feed pipes through which the process fluid is flowed, and controlling the flow of the fluid through the pipes. and one or more valves for regulating. Each of the configurations described herein can include at least one variable frequency drive (VFD) coupled to a respective pump that can control at least one liquid flow rate. In some implementations, liquid flow rate is controlled by at least one flow control valve.

In some embodiments, the flow control system may be operated manually. For example, an operator can set the flow rate for each pump or transfer device and set the open or closed position of a valve to regulate the flow of process fluid through tubing in a flow control system. can. When an operator sets the flow rate and valve open or closed position for all flow control systems distributed across the system, the flow control system operates under a constant flow condition, such as a constant volumetric flow rate or other flow condition. Flow can flow under the . To change flow conditions, an operator can manually operate the flow control system, such as by changing the pump flow rate or the open or closed position of a valve.

In some embodiments, the flow control system may be operated automatically. For example, the flow control system may be connected to a computer or control system (eg, control system 999) to operate the flow control system. The control system may include a computer-readable medium storing instructions (such as flow control instructions and other instructions) that are executable by one or more processing units to perform operations (such as flow control operations). . Operators can use the control system to set flow rates and valve open or closed positions for all flow control systems distributed throughout the facility. In such embodiments, an operator may manually change flow conditions by providing input through the control system.

Also, in such embodiments, the control system automatically (i.e., without manual intervention) controls one or more of the flow control systems, such as by using a feedback system coupled to the control system. ) can be controlled. For example, a sensor (such as a pressure sensor, temperature sensor, leak detection sensor, or other sensor) may be connected to the tube through which the process flow flows. The sensors can monitor and provide flow conditions (such as pressure, temperature, or other flow conditions) of the process fluid to the control system. In response to flow conditions exceeding a threshold (threshold pressure value, threshold temperature value, or other threshold value), the control system can automatically take action. For example, if the pressure or temperature in a pipe exceeds a threshold pressure value or a threshold temperature value, respectively, the control system may send a signal to a pump to reduce the flow rate, a signal to open a valve to relieve pressure, or a signal to the process fluid flow. or other signals may be provided.

For example, FIG. 3 shows the contact angle for the flow conditions of a recovered solution (stream) 302 at a packing surface 304 for a gas-liquid contactor system, such as the gas-liquid contactor 100 shown in FIGS. 1A-1B. Figure 300 depicts the effect of. One cause of insufficient wetting is the low surface energy of the filler. Surface energy represents the strength of intermolecular bonds at the surface of a material and is the energy required to increase the degree of surface exposure. If a material has a high surface energy, its bulk interactions can be stronger and its surface exposure can be greater. This can result in better wetting and hydrophilicity (eg, tendency to attract water). If a material has a low surface energy, the bulk interactions of the material can be weaker and the surface exposure of the material can be smaller. Poor wetting and hydrophobicity (eg, tendency to repel or immiscible with water) are usually associated with large contact angles. The contact angle is defined as the angle between the liquid-solid interface and the liquid-vapor interface, measured through the liquid as shown in FIG. 3. The contact angle can affect the flow conditions of the CO ₂ capture solution flowing in the packing. For example, large contact angles (e.g., contact angles greater than 70 degrees and less than 150 degrees) can result in trickle flow, and small contact angles (e.g., contact angles greater than 20 degrees and less than 50 degrees) can result in film flow. there is a possibility.

For example, for superhydrophobic surfaces, the contact angle can be greater than 150 degrees. For example, for superhydrophilic surfaces, the contact angle can be less than 20 degrees. A large contact angle typically correlates with flow conditions that are closer to the trickle 302 and a smaller wetting area ε (i.e., area of wetted surface); a smaller contact angle is more like a membrane flow 308 and a larger It is typically related to flow conditions that are wet areas. Small contact angles and hydrophilicity generally indicate a high ratio of interfacial area to liquid loading.

_Hydrophilic materials can be Can be used for filling 304 on gas-liquid contactors. Hydrophilic coatings increase surface energy and reduce contact angles. Some surface treatments that expose the material to alter its bond to the surface can also achieve similar results.

In some embodiments, a gas-liquid contactor that includes a packing 304 (as a hydrophilic packing) maintains or improves the pressure drop across the packing while maintaining or improving the shape of the packing to be more suitable for small liquid flow rates. The filler shape, surface structure, and Increasing the CO ₂ capture flux (e.g., by 10% to 30%) through an increase in the specific surface area of the packing 304 by employing an increase in liquid hold-up efficiency of the packing material by managing surface energy. I can do it. Design criteria for hydrophilic fill 304 that reflect good performance include, but are not limited to, low static pressure design, ability to distribute liquid evenly through the fill height, low fouling ability, air There is an increase in contact efficiency, less material requirements, and manufacturability.

Thus, in some cases, the packing 304 in the gas-liquid contactor exhibits hydrophilicity (and reduced contact angle) as opposed to hydrophobicity (and increased contact angle) by the _CO2 recovery solution or may be designed, constructed, and/or modified to include. Such a design also improves wetting of the packing 306 by the CO ₂ capture solution. Enhanced wetting of the filler 306 (eg, increasing the wetted surface area) can be achieved in at least two ways. The first approach is to increase the hydrophilicity of the surface, for example through increasing the surface free energy by applying a coating. The second is to increase the surface roughness and apparent contact angle. The apparent contact angle is the angle between the apparent solid surface (as opposed to the actual solid surface) and the liquid-gas interface, as shown in FIG. These techniques can be used independently or in combination with each other.

In some cases, the filler can be difficult to process (ie, difficult to apply the coating to). In some implementations, the fill coating improves mass transfer for DAC applications where the CO ₂ capture solution is dispensed at liquid fill flow rates including, but not limited to, from 0 L/m ² s to 10 L/m ² s. may be appropriate when For example, a fill coating may be suitable for low liquid filling rates, which may range from 0.5 L/m ² s to 2.5 L/m ² s. These packing coatings may also be useful for dispensing recovery solutions into packings with exemplary packing depths of 2 to 10 meters. In an exemplary implementation, the filling may include a hydrophilic coating applied to increase hydrophilicity.

For example, FIG. 4 shows the contact angle between the hydrophilic coating 400 on the surface of the packing and the recovery solution 410 for a gas-liquid contactor system, such as the gas-liquid contactor 100 shown in FIGS. 1A-1B. An example is shown. FIG. 4 shows an uncoated surface 402, a surface 402 coated with a first acrylic layer 404, a surface 402 coated with a layered acrylic coating, and a surface 402 with a fouling layer 408. It shows. In an exemplary implementation, the layered acrylic coating may include a first acrylic layer 404 and a second acrylic layer 406. In an exemplary implementation, surface 402 may include PVC or other thermoplastic. In some cases, the uncoated filler surface 402 may have a contact angle θ greater than 65 degrees and less than 80 degrees. In some cases, the coating can reduce the contact angle θ to less than 65 degrees. For example, an uncoated filler surface 402 may have a contact angle of 75 degrees, and a coating may reduce the contact angle to 35 degrees.

A type of hydrophilic coating that can be applied to the filler surface 402 is an acrylic coating. Acrylic coatings are a type of coating that can increase the hydrophilicity of the filling. Some of these coatings are commercially available for purposes not related to industrial heat removal or chemical separation.

Two examples of such acrylic coatings are NeoPac and NeoCryl. NeoPac is a high solids aqueous urethane-acrylic hybrid copolymer. When applied to PVC fillings, NeoPac can achieve contact angles greater than 7 degrees and less than 35 degrees, depending on whether it is applied as an acrylic layer alone or as a mixed layer. can. NeoCryl is a self-crosslinking acrylic copolymer emulsion. When applied to PVC fillings, NeoCryl can achieve contact angles greater than 40 degrees and less than 65 degrees, depending on whether it is applied as an acrylic layer alone or as a mixed layer. can. In some cases, acrylic coatings can be mixed and/or layered on top of each other. For example, first acrylic layer 404 can include a majority of a urethane-acrylic hybrid copolymer, and second acrylic layer 406 can include a majority of a self-crosslinking acrylic copolymer emulsion. In other examples, the first acrylic layer 404 may include a urethane-acrylic hybrid copolymer in large part, and the second acrylic layer 406 may include a urethane-acrylic hybrid copolymer and a self-crosslinking acrylic copolymer emulsion. It may also include a mixture with. Examples of proportions for mixing urethane-acrylic hybrid copolymer and self-crosslinking acrylic copolymer emulsion may be 20/80, 80/20, or 50/50, although other proportions are suitable. There is a possibility.

In some embodiments, the hydrophilic coating can include a fouling layer 408 that can increase surface roughness and reduce the contact angle of collection solution 410 to surface 402. For example, in certain DAC applications involving calcium carbonate (CaCO ₃ ) chemistry, the fill surface may be conditioned. Conditioning is the naturally occurring fouling of the filling surface that results in a layer of CaCO ₃ and other accumulations that increases the area of the wetted surface by increasing the surface roughness. For example, fouling layer 408 can reduce the contact angle to between 10 degrees and 40 degrees. The resulting flow is more membranous than a trickle of fresh uncoated and unconditioned packing (ie, packing that is smooth and has no fouling layers or build-up).

Another example of a hydrophilic coating is a cellulose coating. For example, FIG. 5 shows an exemplary cellulose-coated packing 500 for a gas-liquid contactor system, such as gas-liquid contactor 100 shown in FIGS. 1A-1B. The coated filler 500 comprises an adhesive layer 504 and a cellulose layer 506 on a plastic substrate 502, such as a filler sheet. For example, a coating comprising an adhesive layer 504 such as ethylene vinyl acetate (EVA) and a thin layer 506 of cellulose adheres well to PVC. Adhesive coatings such as EVA are not traditionally used as coating materials for PVC fillings in cooling towers or chemical processing industries. EVA and similar adhesive coatings are typically used as laminates for glass structures in the building construction and transportation industries. In some cases, EVA can be applied to the plastic substrate 502 of any sufficiently structurally strong material (eg, filler). In one approach, a layer 506 of cellulose (a single layer as used in some retail paper products) may be hot rolled onto a plastic substrate with heated rollers 508. This process is performed on both sides of the plastic substrate 502. The coating comprising cellulose layer 506, adhesive layer 504, and plastic substrate 502 may be fully compatible with high strength caustic solutions such as KOH and NaOH, respectively. In some cases, this coating can increase wetting with small streams of recovery solution, resulting in greater recovery rates.

Cellulose-coated filler 500 is a laminated plastic and includes an adhesive layer 504 interposed between a cellulose layer 506 and a plastic substrate 502. Adhesive layer 504 can include EVA, and adhesive layer 504 can have a thickness of 30-100 μm. The thickness of cellulose layer 506 can be approximately 50-100 μm. Cellulose is a suitable material for coated fillers because it is hydrophilic, allows solution wicking, and is inexpensive. An important consideration is that the structural integrity of the cellulose is compatible with alkaline recovery solutions since it does not collapse in highly concentrated caustic fluids. Also, cellulose can be easily extracted from the kraft paper process (which involves similar chemistry and reactions to some DAC processes). In some cases, EVA can be a suitable adhesive layer because it is one of the cheapest polymers and can be applied to any type of plastic substrate, including PVC and non-PVC plastic substrates. Can be glued. EVA is compatible with caustic solutions and evaluated for high pH conditions. In some cases, a different adhesive or adhesive material may be used in adhesive layer 504 instead of EVA. For example, PVC glue may be suitable.

In an exemplary process for applying a cellulose layer 506 to a plastic substrate 502 (i.e., a filler), an adhesive layer 504 (e.g., an EVA layer having a thickness of at least 30 μm) is first applied to a plastic substrate 502 (i.e., an EVA layer having a thickness of at least 30 μm). For example, placed in PVC). Next, the adhesive layer 504 is heated to a bonding temperature in the range of 80°C to 130°C. Next, a cellulose layer 506 is placed over the adhesive layer 504. Cellulose layer 506 is then pressed onto adhesive layer 504 using heated rollers 508. This can form a strong bond of cellulose 506 to plastic substrate 502.

In one example, calendering 600 may be used to apply cellulose 604 and adhesive material 608 (eg, EVA or PVC adhesive) to a plastic substrate or filler sheet 602 (eg, a PVC layer). FIG. 6 shows an exemplary calendering process 600 for producing a fill for a gas-liquid contactor system, such as the gas-liquid contactor 100 shown in FIGS. 1A-1B. In the process of polishing the filler sheet 602, other polymeric outer layers can be added to the filler sheet 602. The filler sheet 602 may also be shaped into patterns such as corrugations, grooves, herringbones, or channels using rollers in a process similar to glazing.

As shown in Figure 6, a calender consists of a series of high pressure rollers 606a, 606b, 606c, 606d (collectively Generally, the code is 606). Calendar rollers 606 are also used to form certain types of plastic films and to apply coatings. Some calender rollers 606 are heated or cooled as needed. In some embodiments, calendering 600 may be performed on both sides of filler sheet 602. In some implementations, filler sheet 602 may be formed into a pattern (eg, corrugations, grooves, herringbones, or channels) using a vacuum forming process. The packing sheets 602 may be positioned in contact with each other to form passageways or grooves that are openable to carry the CO ₂ capture solution. Contact between filler sheets 602 can be continuous or intermittent at points along the pattern. Filler sheets 602 may be positioned to form filler areas in a manner similar to that described in FIG. 7.

Instead of, or in addition to, the coating, at least a portion of the surface of the material may be exposed to some surface treatment (not shown) that can effect a change in adhesion at the surface to improve hydrophilicity. can. Examples of such surface treatments are plasma treatments, flame treatments, corona treatments and some chemical treatments with oxidizing agents. Some examples of surface treatments can be mechanical treatments such as bead blasting and embossing. A surface treatment can be applied directly to the surface of the filler layer. In some cases, a surface treatment can be applied to the coating on the surface of the fill layer, especially if the coating is responsive to the surface treatment (eg, the contact angle is reduced and the hydrophilicity of the coating is improved).

In addition to or in addition to the coating and surface treatment, the material composition for the filler (not shown) can be selected to improve hydrophilicity. For example, specific PVC resins and/or vinyl compounds are compatible with several conventional thermoplastics (e.g., acrylics, polyesters, polypropylene, may have higher surface energy than polystyrene, nylon, and Teflon, and may have increased wettability. The contact angle can be used to determine the surface energy of the material, which is one of the factors for meeting hold-up efficiency. The filler material raw material, which may be in the form of a roll stock of vinyl sheets, which may be comprised of high surface energy PVC resin and/or vinyl compounds, can be formed using molds and vacuum forming devices and used as a layer in the filler. can be done.

In addition to or in place of the exemplary hydrophilic configuration of the packing described above, surface roughness can be used to adjust the contact angle of the collection solution to the packing and to reduce the area of the wetted surface. It can also be used to increase The shape of the surface of the filler can be used to adjust the apparent contact angle. The layer of packing can have large macrostructures to influence the "macroscopic" flow, and/or can have microstructures in the layer to influence the contact angle. Macrostructures are corrugations, grooves, herringbones, or channels that affect the tendency of liquid to move backwards, forwards, or straight down in the fill, depending on the air velocity and the stiffness of the fill. It can include patterns such as. Microstructures are small scale patterns or structures that can reduce the apparent contact angle and allow membrane flow of the collected solution.

A textured surface of a layer of filling can be achieved by superimposing a microstructure on a flat filling or on a filling with a macrostructure. Macrostructural, microstructural, or hydrophilic coatings (such as the aforementioned acrylic coatings, EVA coatings, and cellulose coatings) can be used independently or in combination with each other to increase the wetted surface area of the filling. and can be used. Some macro- and microstructures indicate that the CO ₂ recovery solution is dispensed at liquid-fill flow rates ranging from 0L/m ² s to 10L/m ² s, and with filling depths such as 2 to 10 meters. It is particularly suitable for improving mass transfer for DAC applications distributed in packings with In some cases, the macrostructure and microstructure in the packing are suitable for liquid filling rates from 0.5 L/m ² s to 2.5 L/m ² s.

An example of a filling with macrostructures is a corrugated filling 700. For example, FIG. 7 shows a perspective view of the corrugated packing sheets 702, 704 of the packing, and the corrugated A front view of rim 708 is shown. The corrugated filler sheets 702 and 704 have at least one corrugated edge 708 and at least one smooth edge 706. Smooth edge 706 may be substantially perpendicular to wavy edge 708. The corrugated filler sheets 702 and 704 may have corrugations that form a particular cross-sectional shape having peaks 710 and valleys 712, as depicted by the front view of the corrugated edges 708. The exemplary corrugated fill layer 702 includes trapezoidal corrugations. The exemplary corrugated fill layer 704 includes triangular corrugations. In some cases, the corrugated filler sheet may form both trapezoidal and triangular corrugations. In some cases, the corrugated edge 708 may form other cross-sectional shapes not shown.

The corrugated packing sheets 702, 704 may be suspended so that the solution flows down along the corrugations 708 in a direction that is substantially parallel to the smooth edges 706 (eg, flow direction corrugations). In this case, only the tensile strength of the filler sheets 702, 704 needs to be considered, since the corrugations in the flow direction are relatively unaffected by liquid loading. In some cases, corrugated packing sheets 702, 704 having corrugations may be positioned such that the solution flows across the corrugations in a direction that is substantially parallel to the edges of the corrugations (e.g., cross-flow corrugations). .

In some embodiments of the infill, the infill sheet is suspended from the depending bar such that the corrugated edges of the corrugated infill sheet are aligned with the axis of the horizontal depending bar (similar to a curtain). . In some implementations, the filler sheets may be suspended at least 0.2 inches apart from each other. For example, the filler sheets can be suspended at least 0.5 inch apart from each other. For example, filler sheets can be hung 0.25 inches apart from each other. The spacing between the sheets can determine the pressure differential (smaller spacing results in a larger pressure differential). The sheets should be arranged so that the corrugations of the sheets are at least partially aligned with each other. For example, the distance between the top of the first corrugated sheet and the top of the second corrugated sheet is the distance between the trough of the first corrugated sheet and the trough of the second corrugated sheet. It can be equivalent to The CO ₂ recovery solution can be distributed (in cocurrent or countercurrent with the gas flow) by flowing from the upper liquid sump 204 or via a spray feed.

Other examples of macrostructures in the fill area include channels or grooves. In some embodiments, one corrugated sheet 702, 704 can be positioned in contact with another corrugated sheet 702, 704 such that the corrugations form a passageway operable to carry collection solution. In some implementations, the corrugated sheets 702, 704 can press against each other. In some implementations, corrugated sheets 702, 704 can be secured to each other (eg, mechanically attached). For example, the corrugated peaks 710 of the corrugated sheets 702, 704 may at least partially contact the corrugated troughs 712 of the other corrugated sheets 702, 704, thereby forming a groove or passageway therebetween. can. Contact between the corrugated sheets 702, 704 may be continuous or intermittent at points along the corrugations. The packing area can include packing sheets that form passages that are less steep (allowing for a more gradual flow of collected solution) than those formed in conventional packings. For example, the packing section can include 15 degree passages (as opposed to the 45 degree passages typically found in gun cooling tower packing). In some implementations, the macrostructures may include dimensions ranging from 0.5 inches to 4 inches. For example, the corrugations may have a width of 1 inch and a height of 0.5 inch.

FIG. 8 illustrates one or more sets of progressive passages 802a, 802b (collectively labeled 802) for a gas-liquid contactor system, such as the gas-liquid contactor 100 shown in FIGS. 1A-1B. A packing area 800 is shown with a forming packing sheet. In some cases, the fill area 800 may include a progressive passageway 802 and an optional hydrophilic coating (such as coating 400 as described with reference to FIG. 3). The progressive passageway 802 can improve liquid distribution in the vertical plane of the fill area 800 (ie, can improve liquid distribution from front to back). The progressive passage 802 can also reduce pressure drop. In some cases, a hydrophilic coating or surface treatment may be applied to at least a portion of one or more filler sheets prior to incorporation into filler section 800 that includes progressive passageway 802. The progressive passageway 802 may include a passageway that is at an angle of 45 degrees or less (eg, is sloped). For example, the progressive path 802 can be selected from a range of about 15 degrees to about 45 degrees.

In some implementations, the first set of progressive passageways 802a is positioned at a smaller angle than the second set of progressive passageways 802b. For example, a first set of progressive passages 802a may be positioned at an angle of 15 degrees, and a second set of progressive passages 802b may be positioned at a different angle that is less than or equal to 45 degrees (i.e., slope A is 15 degrees). (Inclination B is 45 degrees or less). In some implementations, the first set of progressive passages 802a and the second set of progressive passages 802b are positioned at similar angles. For example, both the first and second sets of progressive passageways 802 are positioned at an angle of approximately 15 degrees (ie, slope A and slope B are both approximately 15 degrees). In some cases, the first set of progressive passages 802a is at a non-parallel angle to the second set of progressive passages 802b. In some cases, including but not limited to the implementations described above, the passageway angle is adjusted to affect liquid distribution toward the process set point (air velocity and liquid flow). It can be adjusted within the range of 45 degrees to 15 degrees.

Microstructures can be superimposed on macrostructures to increase the wetted surface area in the filler sheet. FIG. 9 shows an example of a microstructure 1200 in a packing sheet for a gas-liquid contactor system, such as gas-liquid contactor 100 shown in FIGS. 1A-1B. The microstructures 1200 in the packing 106 can be very small scale features that enhance wetting by the collection solution 1202 through the effect of the apparent contact angle (as the opposite of the actual contact angle). The size of the microstructures 1200 can be on the millimeter scale, in contrast to the macrostructures, which can range from 0.5 inches to 4 inches.

An example of a microstructure 1200 that can be used to achieve a small apparent contact angle is a ridge 1204. In some implementations, ridges 1204 may have a width of less than 10 mm. For example, ridges 1204 may be sized between 1 mm and 2 mm. Ridges 1204 are cross-flow ridges that can be used to achieve better wetting by recovery solution 1202 compared to a surface without microstructure. For example, Figure 9 shows a comparison of liquid flow in a normal flat packing sheet to liquid flow in a 1 mm cross-flow ridge in the packing sheet.

Certain microstructures 1200 may protrude from the layer surface of the filler. In some implementations, the microstructures 1200 protruding from the layer surface of the filler may include a different material than the layer surface of the filler. For example, granules 1212 or fibers 1210 may be introduced into the layer of filler during manufacturing to increase the surface roughness of the layer of filler that was initially smooth. By adding fibers 1210 to the layer of filler, a texture that is similar to fiberglass sheets can be achieved. Certain microstructures can be depressed into the layer surface of the filler. For example, dimples 1206, etches 1208, perforations, perforations, or combinations thereof may be introduced to increase the surface roughness of an initially smooth layer of filler. A layer of filler is inscribed using a roller wire brush or other similar tool with fine rigid components. The size, spacing, and shape of these microstructures reduce the apparent contact angle (e.g., to below 50 degrees) for liquid fill flow rates ranging from 0 L/m ² s to 10 L/m ² s, etc. selected as follows. In some cases, the microstructure is configured to reduce the contact angle for small liquid fill rates ranging from 0.5 L/m ² s to 2.5 L/m ² s.

For example, FIG. 10 shows that for a gas-liquid contactor system, such as the gas-liquid contactor 100 shown in FIGS. 1A-1B, the intersecting flow ridges 1302, flow direction, and FIG. 1300 shows a diagram 1300 comparing the contact area of fillers with ridges 1308 and no ridges (flat) 1314. Cross-flow ridges 1302 and flow direction ridges 1308 form narrow, raised striations on the surface of the filler sheet having dimensions on the millimeter scale. Ridges can be described in terms of how the streaks are oriented with respect to the direction of liquid flow. Cross flow ridges 1302 may be oriented in a direction substantially non-parallel to the CO ₂ capture solution flow direction. In some cases, the cross-flow ridges 1302 can be oriented perpendicular to the flow direction of the CO ₂ capture solution. Flow direction ridges 1308 can be oriented in a direction that is substantially parallel to the direction of liquid flow.

At large liquid flow rates, the cross flow ridges 1306 can achieve a wetter surface area (interface area) than the flow direction ridges 1312 and the flat plate 1318. Similarly, at small liquid flow rates, the cross flow ridges 1304 can achieve a wetter surface area (interface area) than the flow direction ridges 1310 and the flat plate 1316. A small flow rate of collected solution is preferred in the gas-liquid contactor 100 to reduce liquid pumping requirements, and therefore the packing containing cross-flow ridges 1302 may have flow direction ridges 1308 or flat plates 1314. may be more beneficial under these operating conditions. In some cases, flow direction ridges 1308 may be beneficial to direct the flow of gas or to redirect the flow of CO ₂ capture solution. Modeling shows that a 1 mm cross-flow ridge 1302 can achieve a wetting area greater than 0.95 by tilting the contact surface such that a small apparent contact angle is achieved. Flow direction ridges 1308 can improve wetting relative to flat packing 1314, but the improvement is not as great as cross flow ridges 1302.

Microstructures and/or macrostructures may be shaped through one or more processes. Exemplary processes are mold and vacuum forming. In an exemplary embodiment, the process includes the steps of creating a mold (e.g., using a 3-D printer) having opposites of both macrostructure and microstructure and filling material (e.g., blank/flat (a thermoplastic such as PVC) to a forming temperature of 110°C to 150°C, stretching the sheet of filler material into a mold, and applying a vacuum to force the sheet of filler material into the mold. and applying. In other exemplary embodiments, the process includes creating a mold (e.g., using a 3-D printer) that has the opposite of only the macrostructure and a sheet of filler material (e.g., using a 3-D printer) that already has the microstructure ( (e.g., a sheet of thermoplastic material with dimples or 1 mm ridges) to the molding temperature, placing the sheet of filler material in the mold, and vacuuming the sheet of filler material in contact with the mold. and applying.

In other exemplary embodiments, the process includes creating a mold (e.g., using a 3-D printer) having only the opposite microstructure and a sheet of filler material (e.g., a blank/flat applying a sheet of filler material to a mold; and applying a vacuum to force the sheet of filler material against the mold. Types can range from 2"x2" to at least 10'x10'. In some embodiments, the size of the printed mold can be a 2'x2' mold or a 6"x6" mold.

As another example process, filler 106 may be printed directly including printing macrostructures and/or microstructures using a 3D printer. In another exemplary process, the filling 106 may be 3D printed with a soft tool (eg, clay) or a hard tool, each of which may be used to fabricate a mold for manufacturing the filling.

FIG. 11 shows a gas-liquid contactor system, such as the gas-liquid contactor 100 shown in FIGS. 14 illustrates an example technique 1400 for forming structure 1406. In certain applications where microstructure 1406 is desired, soluble solids 1402 may be introduced prior to installing filler material 1404 into the _CO2 capture system. At a later stage, a conditioning step is taken in which the soluble solid 1402 is dissolved with a dissolving fluid (e.g., acid, caustic solution, CO ₂ capture solution, etc.) to create microstructures 1406 such as depressions, ridges, or perforations. The texture of the filling material 1404 is changed by leaving it. Dissolvable solids 1402 may be added during manufacture and/or coating of filler material 1404. For example, soluble solids 1402 can be introduced into a filler material 1404 that includes PVC resin and/or vinyl compounds. In some applications, the soluble solids 1402 are not introduced into the filler material stock 1404, but as part of a coating on a formed sheet of filler material 1404.

At a later stage, such as during conditioning of the charge or during initiation of the process of a gas-liquid contactor containing the charge, the dissolvable solids 1402 may be dissolved in the dissolving fluid. Disappearance of the soluble solid 1402 can change the texture of the filler material 1404 by leaving behind the microstructure 1406. Some examples of soluble solids 1402 that can be used for this feature are silica compounds, calcium carbonate (CaCO ₃ ), potassium carbonate (K ₂ CO ₃ ), or similar solids that can be dissolved in the dissolution fluid. be. For example, the dissolution fluid can be a chemical wash (eg, an acid) applied in the conditioning step, or a caustic recovery solution. Chemical washing may involve dissolving soluble solids 1402 in solutions such as dilute acetic acid, vinegar, or NaCl. The conditioning step may involve dissolving the soluble solids 1402 with a caustic recovery solution such as KOH or NaOH. In some cases, the dissolving fluid is water or steam that dissolves certain soluble solids 1402, such as water-soluble salts or minerals (e.g., calcium, sodium, chlorides, bicarbonates, sulfates, organics, etc.). It can be. In some cases, the dissolution fluid may be heated to increase the rate of dissolution of the dissolvable solids 1402.

Together with increasing the surface energy (e.g., through coatings) and decreasing the contact angle of the filler (e.g., through macro- and microstructures), CO ₂ capture solutions are an approach to increase hydrophilicity. may be formulated and/or applied. For example, delivery of an atomized CO ₂ capture solution that produces an atomized spray of droplets of CO ₂ capture solution can be used to utilize the wetted surface area. FIG. 12 shows the interaction 1500 of a spray solution with a liquid interface layer 1504 for a gas-liquid contactor system, such as the gas-liquid contactor 100 shown in FIGS. 1A-1B.

Spray solution delivery can be combined with any of the packing designs (hydrophilically coated packings, packings with macrostructures, packings with microstructures, or combinations thereof) to increase the wetted surface area. Can be used. In certain embodiments, the spray solution droplets 1506a, 1506b (collectively labeled 1506) are small enough to be effectively transported by the gas in the direction of gas flow. The distribution of sprayed (non-atomized) liquid at a typical cooling tower nozzle is typically a bulk flow, with mostly larger droplets transported via gravity.

The CO ₂ capture solution can be distributed to the packing as an atomized spray simultaneously with the gas flow to improve performance. The surface requires a minimum wetting flow or liquid flow (CO ₂ capture solution flow rate) to achieve a certain amount of wetting. In some cases, in small liquid flows, if a hydrophilic surface, or a surface with an optimal contact angle, is used, the spray solution droplets 1506 will be less wet (e.g., compared to droplets without spray). can be increased. In some cases, in large liquid flows, spray solution droplets 1506 may not significantly enhance wetting (e.g., compared to droplets without spray) if a hydrophobic surface is used. be. Large liquid flows can result in turbulent flow of the atomized solution droplets 1506, and absorption of the atomized solution droplets 1506 into the bulk solution can be hindered by the turbulent flow of the solution at large wetting flow rates. If the filler is hydrophobic, the spray solution droplets 1506 will be less effective because the bulk solution layer 1502 will become smaller as the droplets form.

If the filler is hydrophilic, the spray solution droplets 1506 can be more effective because the bulk solution layer 1502 becomes larger due to spreading. The bulk solution layer 1502 is determined in part by the selected spray flow rate and not necessarily by the minimum wetting flow. If the specific surface area is increased due to hydrophilicity or by adopting small-scale structures at the surface, the area of the active liquid interface increases continuously by replenishing droplets 1508a, 1508b. Can be replenished. Replenishing droplets 1508 are droplets of spray solution that replenish the liquid interface layer 1504, which can affect reaction rates. In large scale systems, the liquid flow at the bottom of the packing can even be rather large. It may be necessary to selectively divert this flow through the packing at graded levels.

As another example of a modification to a conventional CO ₂ capture solution, the CO ₂ capture solution may have one or more additives that increase its hydrophilicity and/or increase the rate of transfer of gaseous CO ₂ into the solution. Enzyme compounds or catalysts can be included. For example, it may be beneficial to implement rate-enhancing additives in a gas-liquid contactor containing a charge (eg, gas-liquid contactor 100 of FIGS. 1A-1B). Speed-enhancing additives can increase the rate of movement of _CO2 from the gas to the _CO2 capture solution. Speed-enhancing additives may include catalysts, promoters, solvents, or other types of additives. Examples of speed-enhancing additives include, for example, carbonic anhydrase, piperazine, MEA, DEA, zinc triazacycyl, zinc tetraazacycyl, copper glycinate, hydroxopentamine cobalt perchlorate, formaldehyde hydrate, sucrose. , fructose, glucose, phenol, phenolate, glycerin, arsenite, hypochlorite, hypobromite, or other oxyanion species.

In some cases, the rate-enhancing additive can move freely in the _CO2 recovery solution flowing across the packing. In some cases, the rate-enhancing additive may be immobile in the capsule, moving freely in the CO ₂ capture solution flowing across the fill. If the speed-enhancing additive is freely moving, it can be confined within the gas-liquid contactor and prevented from flowing to the regeneration system by a barrier or filtration system. .

In some cases, it may be advantageous to coat the surface of the packing with a rate-enhancing material containing rate-enhancing additives such as promoters or catalysts that are stabilized in a solid support by an immobile method. For example, at least one of the microstructure, macrostructure, or smooth surface of the filler sheet can be coated with a speed-enhancing material.

In some cases, it may be advantageous to mix the raw filler material raw material used in manufacturing the filler with speed-enhancing additives. For example, the filler sheet may include a mixture of PVC and a resin that carries a promoter or catalyst. In this case, the promoter or catalyst can be stabilized in a solid support in the resin. In some applications, free-moving rate-enhancing additives in the collection solution, rate-enhancing materials coated on the surface, rate-enhancing materials mixed within the packing material, or combinations thereof improve CO ₂ uptake. It can be used to make

FIG. 13 is a schematic diagram of a control system (or controller) 1600 for a gas-liquid contactor system, such as gas-liquid contactor 100 shown in FIGS. 1A-1B. System 1600 may be described in connection with any of the computer-implemented methods described above, such as as or as part of control system 999 or other control devices described herein. It can be used for operations that

System 1600 is intended to include various forms of digital computers, such as laptop computers, desktop computers, workstations, personal digital assistants, servers, blade servers, mainframes, and other suitable computers. System 1600 may also include mobile devices such as personal digital assistants, cell phones, smartphones, and other similar computing devices. The system may also include portable storage media such as a Universal Serial Bus (USB) flash drive. For example, a USB flash drive can store operating systems and other applications. A USB flash drive may include input/output components, such as a wireless transmitter or a USB connector that can be inserted into a USB port on another computing device.

System 1600 includes a processing unit 1610, memory 1620, storage device 1630, and input/output device 1640. Each of components 1610, 1620, 1630, and 1640 are interconnected using system bus 1650. Processing unit 1610 can process instructions for execution within system 1600. Processing devices can be designed using any of several architectures. For example, processing device 1610 may be a CISC (complex instruction set computer) processing device, a RISC (reduced instruction set computer) processing device, or a MISC (minimum instruction set computer) processing device.

In some implementations, processing device 1610 is a single-threaded processing device. In some implementations, processing device 1610 is a multi-threaded processing device. Processing unit 1610 may process instructions stored in memory 1620 or storage device 1630 to display graphical information about a user interface on input/output device 1640.

Memory 1620 stores information within system 1600. In some implementations, memory 1620 is a computer readable medium. In some implementations, memory 1620 is a volatile storage unit. In some implementations, memory 1620 is a non-volatile storage unit.

Storage device 1630 can provide mass storage to system 1600. In some implementations, storage device 1630 is a computer readable medium. In various different implementations, storage device 1630 can be a floppy disk device, a hard disk device, an optical disk device, or a tape device.

Input/output device 1640 provides input/output operations to system 1600. In some implementations, input/output device 1640 includes a keyboard and/or pointing device. In some implementations, input/output device 1640 includes a display unit for displaying a graphical user interface.

The particular features described may be implemented in digital electronic circuitry, computer hardware, firmware, software, or combinations thereof. The apparatus may be implemented in a computer program product tangibly embodied in an information carrier such as a machine-readable storage device for execution by a programmable processing device, and the method steps perform the functions of the described implementation. It may be implemented by a programmable processing device that executes a program of instructions to perform operations on input data and generate output. The described features include receiving data and instructions from a data storage system, at least one input device, and at least one output device; The invention may advantageously be implemented in one or more computer programs executable in a programmable system, including at least one programmable processing device connected for transmission to an output device. A computer program is a set of instructions that can be used, directly or indirectly, in a computer to perform a particular activity or cause a particular result. A computer program can be written in any form of programming language, including compiled or interpreted languages, for deployment as a stand-alone program, or for use in a module, component, subroutine, or computer environment. It can be deployed in any form, including deployment as other suitable units.

Suitable processing units for the execution of a program of instructions include, by way of example, both general and special purpose microprocessors, and may include a single processing unit or a number of processing units of any type of computer. There is one. Generally, a processing device will receive instructions and data from read only memory, random access memory, or both. The essential elements of a computer are a processing unit for executing instructions and one or more memories for storing instructions and data. Generally, the computer also includes, or is operably connected to communicate with, one or more mass memories for storing data files, and such memory includes an internal hard disk drive. and magnetic disks, magneto-optical disks, and optical disks, such as removable disks. Memory suitable for tangibly embodying computer program instructions and data includes, by way of example, semiconductor memory devices such as EPROM, EEPROM, and flash memory devices, magnetic disks such as internal hard disks and removable disks, and magneto-optical disks. There are all forms of non-volatile memory, including CD-ROM disks and DVD-ROM disks. The processing unit and memory can be supplemented by or integrated into an ASIC (Application Specific Integrated Circuit).

In order to provide interaction with the user, there is a display device such as a CRT (cathode ray tube) or LCD (liquid crystal display) monitor to display information to the user, a keyboard, and a computer that allows the user to input information. The features may be implemented in a computer having a pointing device such as a mouse or trackball that may be provided. Also, such activities may be performed via touch screens, flat panel displays, and other suitable mechanisms.

Features include a control system that includes back-end components such as a data server, a control system that includes middleware components such as an application server or an Internet server, and front-end components such as a client computer with a graphical user interface or Internet browser. or any combination thereof. The components of the system may be connected by any form or medium of digital data communication, such as a communications network. Examples of communication networks include local area networks (“LANs”), wide area networks (“WANs”), peer-to-peer networks (with ad hoc or static members), grid computing infrastructures, and the Internet.

Several embodiments of the present disclosure have been described. Nevertheless, it is understood that various changes can be made without departing from the spirit and scope of the disclosure. Accordingly, other embodiments are within the scope of the following claims. Further modifications and alternative embodiments of various aspects will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. It is to be understood that the forms shown and described herein are to be considered as example embodiments. Elements and materials may be substituted for those illustrated and described herein, and parts and processes may be reversed, as will be all clear to those skilled in the art after having the benefit of this description. and certain features may be used independently. Changes may be made in the elements described herein without departing from the spirit and scope as set forth in the following claims.

100, 100a, 100b gas-liquid contactor
104 Liquid distribution system
105 Upper liquid reservoir
106 Filling, filling area
110 Lower liquid reservoir
112 fan
114 _CO2 recovery solution
118 Gas intake part
200 Gas-Liquid Contactor
201 Structural members
202 frame
204 Upper liquid reservoir
206 Filling
208 Plenum
210 Lower liquid reservoir
212 fan
214 _CO2 recovery solution
216 Housing
300 figures
302 Recovery solution (flow)
304 Filling surface, filling
306 Filling
400 Hydrophilic coating
402 Filling surface
404 First acrylic layer
406 Second acrylic layer
408 Fouling layer
410 Recovery solution
500 fillings
502 Plastic base material
504 Adhesive layer
506 cellulose layer
600 Calendar processing
602 Plastic base material, filling sheet
604 Cellulose
606, 606a, 606b, 606c, 606d calendar roller
608 Adhesive materials
700 corrugated filling
702, 704 corrugated filling sheet, corrugated filling layer
706 smooth edges
708 Wavy edge
710 Top
712 Tanibe
800 Filling area
802, 802a, 802b progressive passage
999 control system
1200 Microstructure
1202 Recovery solution
1204 Intersecting flow ridges
1210 Fiber
1212 Granules
1300 figures
1302, 1304, 1306 Intersecting flow ridges
1308, 1310, 1312 Flow direction ridges
1314, 1316, 1318 Flat plate without ridges
1400 methods
1402 Soluble solids
1404 Filling materials
1406 Microstructure
1500 interactions
1502 Bulk solution layer
1504 Liquid boundary layer
1506, 1506a, 1506b spray solution droplets
1508, 1508a, 1508b droplets
1600 Control systems, control devices
1610 Processing equipment
1620 memory
1630 storage device
1640 Input/Output Device θ Contact Angle

Claims (45)

A system for removing _CO2 from a dilute gas mixture, the system comprising:
a frame including a plurality of structural members;
at least one filled area comprising one or more filled sheets, the one or more filled sheets comprising a plurality of macrostructures;
one or more reservoirs positioned at least partially below the at least one fill area and configured to retain a CO ₂ capture solution;
at least one fan positioned to circulate CO2 _- containing gas through the at least one fill area;
a liquid distribution system configured to flow the _CO2 recovery solution to the at least one packing area. 5. The at least one packing section and the fan are configured to flow the _CO2- containing gas through the at least one packing section in a cross-flow configuration with respect to the _CO2 recovery solution. The system described in 1. 4. The at least one packing section and the fan are configured to flow the _CO2- containing gas through the at least one packing section in a countercurrent configuration with respect to the _CO2 recovery solution. The system described in 1. The liquid distribution system includes:
one or more upper reservoirs positioned at or near the top of the frame;
one or more redistribution systems positioned in the at least one fill area below the one or more upper liquid reservoirs;
2. The system of claim 1, comprising: one or more sump portions positioned at or near a bottom portion of the frame. the one or more filler sheets comprising a first set of progressive passages at a first angle and a second set of progressive passages at a second angle greater than the first angle; The system according to claim 1. 6. The system of claim 5, wherein the first angle is 15 degrees and the second angle is 45 degrees or less. 2. The system of claim 1, wherein the one or more filler sheets comprise a hydrophilic surface coating. 2. The system of claim 1, wherein the one or more filler sheets include a hydrophilic surface treatment including at least one of plasma treatment, flame treatment, corona treatment, or chemical treatment. 2. The system of claim 1, wherein the plurality of macrostructures comprises at least one of corrugations, grooves, herringbones, or passages. 10. The system of claim 9, wherein the one or more filler sheets further comprise a plurality of microstructures. 11. The system of claim 10, wherein the plurality of microstructures comprises a plurality of ridges that are non-parallel to the corrugations. 12. The system of claim 11, wherein the waveform is aligned with a direction of flow of the _CO2 recovery solution from the one or more reservoirs to the at least one packing area. 12. The system of claim 11, wherein the plurality of microstructures comprises at least one of ridges, depressions, pores, etchings, granules, fibers, perforations, or combinations thereof. 14. The system of claim 13, wherein the ridge comprises a plurality of intersecting flowing ridges. 8. The system of claim 7, wherein the hydrophilic surface coating comprises a cellulose layer and at least one of an EVA layer or a PVC adhesive layer. 8. The system of claim 7, wherein the hydrophilic surface coating comprises at least one acrylic coating. 17. The system of claim 16, wherein the at least one acrylic coating comprises at least one of a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion. The at least one acrylic coating comprises:
a first acrylic layer comprising the urethane-acrylic hybrid copolymer or the self-crosslinking acrylic copolymer emulsion;
18. The system of claim 17, comprising a second acrylic layer comprising the urethane-acrylic hybrid copolymer mixed with the self-crosslinking acrylic copolymer emulsion. 19. The system of claim 18, wherein the urethane-acrylic hybrid copolymer is mixed with the self-crosslinking acrylic copolymer emulsion in a ratio of one of 20/80, 80/20, or 50/50. . 2. The system of claim 1, wherein the one or more filler sheets include a hydrophilic material composition. 21. The system of claim 20, wherein the hydrophilic material composition comprises a PVC resin or a vinyl compound. 21. The system of claim 20, wherein the hydrophilic material composition is formed into one or more layers of hydrophilic filler material by a mold and vacuum forming process. 2. The system of claim 1, wherein the _CO2 capture solution comprises a low surface tension _CO2 capture solution. 2. The system of claim 1, wherein the one or more filler sheets include at least one of a speed-enhancing additive or a speed-enhancing coating. 2. The system of claim 1, wherein the one or more filler sheets include a plurality of soluble solids. 26. The system of _claim 25, wherein the plurality of soluble solids comprises at least one of calcium carbonate ( _CaCO3 ) or potassium carbonate ( _K2CO3 ). 2. The system of claim 1, wherein the _CO2 recovery solution comprises a caustic recovery solution. A method of operating a system for capturing carbon dioxide (CO ₂ ), the method comprising:
flowing a dilute gas mixture comprising _CO2 into one or more packing sections of the gas-liquid contactor;
flowing a recovery solution across the one or more packing sections of the gas-liquid contactor, the one or more packing sections including at least one packing sheet, and the one or more packing sections comprising at least one packing sheet; the filler sheet comprises a plurality of macrostructures;
reacting the dilute gas mixture with the recovery solution to produce _CO2 dilute gas;
operating a fan to release the _CO2 dilute gas from the gas-liquid contactor. 29. The method of claim 28, wherein the at least one filler sheet comprises a hydrophilic coating covering at least a portion of the at least one filler sheet. 30. The method of claim 29, wherein the hydrophilic coating comprises at least one acrylic coating. 31. The method of claim 30, wherein the at least one acrylic coating comprises at least one of a urethane-acrylic hybrid copolymer or a self-crosslinking acrylic copolymer emulsion. The at least one acrylic coating comprises:
a first acrylic layer comprising the urethane-acrylic hybrid copolymer or the self-crosslinking acrylic copolymer emulsion;
and a second acrylic layer comprising the urethane-acrylic hybrid copolymer mixed with the self-crosslinking acrylic copolymer emulsion. 33. The method of claim 32, wherein the urethane-acrylic hybrid copolymer is mixed with the self-crosslinking acrylic copolymer emulsion in a ratio of one of 20/80, 80/20, or 50/50. . 30. The method of claim 29, wherein the hydrophilic coating comprises a cellulose layer and an adhesive layer comprising at least one of EVA or PVC adhesive. 30. The method of claim 29, wherein the hydrophilic coating comprises a fouling layer. 29. The method of claim 28, wherein the plurality of macrostructures comprises at least one of corrugations, grooves, herringbones, or passages. 29. The method of claim 28, wherein the at least one filler sheet comprises a plurality of microstructures. 38. The method of claim 37, wherein the plurality of microstructures comprises at least one of perforations, ridges, depressions, pores, etchings, granules, or fibers. 39. The method of claim 38, wherein the ridges comprise a plurality of intersecting flowing ridges. Flowing the dilute gas mixture comprising CO ₂ into one or more packing sections of the gas-liquid contactor includes flowing the dilute gas mixture containing CO 2 into an intake plenum positioned below the one or more packing sections. 29. The method of claim 28, comprising drawing in a dilute gas mixture. Flowing the dilute gas mixture comprising CO ₂ to one or more packing sections of the gas-liquid contactor includes directing the dilute gas mixture through the one or more packing sections to the recovered solution. 41. The method of claim 40, comprising circulating in an average gas flow direction that is parallel to an average liquid flow direction of . Flowing the recovery solution across the one or more packing sections of the gas-liquid contactor comprises flowing the recovery solution at a liquid fill rate ranging from 0 L/m ² s to 10 L/m ² s. 29. The method of claim 28, comprising flushing. 29. The method of claim 28, wherein the at least one filler sheet comprises a plurality of soluble solids. 44. The method _of claim 43, wherein the plurality of soluble solids comprises at least one of calcium carbonate ( _CaCO3 ) or potassium carbonate ( _K2CO3 ). 29. The method of claim 28, wherein the recovery solution comprises a caustic solution.

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